INTERNSHIP REPORT

MALMO FOODS (PVT) LIMITED,

LAHORE
BY
ZOHAIB ARSHAD
12203
(2020-GCUF-01709)
A REPORT SUBMITTED IN THE FULFILLMENT OF THE
REQUIRMENTS FOR THE DEGREE

OF

BS(HONS.) Food science and Technology

Session: 2020 – 2024

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INTERNSHIP IN BRIEF

I had the opportunity to pursue my internship at Malmo Foods (Pvt.) Limited, Lahore for a
period of 08 weeks. I was selected as an Intern, and I worked at Quality Assurance Department
of Dairy Sector under the supervision of Mr. Tahir Arshad. I gained experience in the Milk
Reception Lab doing fundamental quality tests on raw milk. I also performed quality checks on
processed milk and milk products, such as cream, cheese, desi ghee, butter, ice cream, khoya,
powder milk, and pasteurized milk. Additionally, I tested the quality of mineral water. All of
these testing were carried out to make sure that all products complied with Malmo's quality
standards.

I also had the opportunity to go to processing facilities and observe whole production line and
learn how all of these products were produced and packaged. Every now and then, I was given
the assignment to go to the plant and compile a report on the workers' personal hygiene to
determine whether all quality procedures are being followed.

Overall, it was a fantastic learning opportunity that greatly increased my understanding of how
the quality assurance department operates to uphold high standards. Additionally, the workforce
as a whole was quite cooperative and polite, and the working environment was very professional.

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Dedication

We would like to dedicate this humble effort to the caliph of all the Prophets, the sun of pious,
the obligatory of whole humanity Hazrat Muhammad (‫ )ﷺ‬and to my beloved teachers who made
me think that nothing in this world is unattainable, my loving parents who designed a self-
confidence and leadership in myself, my brothers and sisters for their continuous support for us
and to those who love us and to those who live just for us.

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ACKNOWLEDGEMENT

I had a fantastic chance to learn and advance my career during my internship at Malmo Foods Pvt. Ltd. I
therefore think of myself as a really fortunate person because I was given the chance to take part in it.
Having the opportunity to meet so many lovely people and professionals who guided me through this
internship time makes me grateful as well.

I am especially thankful to Dr. Muhammad Imran (Associate Professor, Department of Food Science
and Technology, Government College University Faisalabad) and all teaching faculty of the
Department of Food Science and Technology who directed me on each step of my internship and whose
guidance provided me a chance to recognize and improve my abilities.

I would like to express my sincere appreciation to Mr. Tahir Arshad (In charge of the Quality Control
lab) and Mr. Mudassar Farooq (lab Supervisor) for their thoughtful and priceless guidance, which was
tremendously helpful for our work both theoretically and practically. Additionally, I'm grateful to Mr.
Faisal and Mr. Farooq (Lab analysts). They were a great help to me during the lab work. Finally, I
would like to express my gratitude to the entire Malmo Foods (lab) staff members.

This chance, in my opinion, will help me advance professionally, In order to achieve my intended career
goals, I will make every effort to utilize newly acquired skills and information to the fullest extent
feasible and to keep working to enhance them, I look forward to cooperation with every one of you in the
future.

MAY ALLAH BLESS THEM ALL!

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Table of Index
Sr. # Subject
1 Preface
2 Introduction Of Malmo foods
3 Olden times of Malmo Foods
4 Mission & Vision
5 Certifications
6 Malmo Food Products
7 Milk Sampling And Raw Milk Testing
8 Powder Milk Tests
9 Water Tests
10 Pasteurization Section
11 Evaporator Plant
12 Milk Powder Plant
13 Ice Cream Section
14 Cheese Section
15 Butter Section
16 Desi Ghee Section
17 Khoya Section
18 Water Section
19 CIP Section
20 Bakery Section
21 Swot Analysis

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Preface

Introduction:
This report covers the activities and responsibilities that I performed during my internship at
Malmo Foods (Pvt.) Limited. Malmo Foods is the National Company with a burning passion to
take on the international market. The report starts with the introduction of the company, then the
mission and the vision of the organization and its structure covering all the departments.
Food is among the basic necessity of life. It not only enables us to survive but also provides
appropriate amounts to ensure a better standard of living by contributing to our health and
wellness. Consumer needs and expectations associated with a particular food product are not
fixed, but change with time, culture, beliefs and as per the geographical distribution of mankind
on Earth.

Dairy:
A dairy is a business enterprise established for the harvesting or processing of animal milk
mostly from goats, sheep or camel for human consumption. A dairy is a typically located on a
dedicated dairy farm or section of multipurpose farm that is concerned with the harvesting of
milk.

Technology:
The Science and the application of scientific, economic as well as sociological knowledge and
legal rules for the production of Raw material and their further processing into semi-finished and
finished products.

Process technology:
Deals with the conversion of raw material into finished products.

Dairy technology:
Dairy technology is a division of engineering that deals with the processing of milk and milk
products. Dairy technology study involves processing, storage, packaging and transportation of
dairy products by implying the science of nutrition and biochemistry.

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Introduction of Malmo Foods

Malmo Foods is managed by a board of Directors who have vested the control of the company
operations with the Chief Executive (CE). The CE is nominated as a person with overall
responsibility for all matters relating to quality. CE is supported by a number functional heads of
departments, including a full time Management representative, responsible for maintenance of
the ISO 9001 quality management systems.
Job descriptions define responsibilities, authorities and roles of all key staff members, who are
encouraged to initiate action to prevent non-conformance. Staff members are authorized to
identify problems related to products, the process, or quality management system, and to
recommend solutions through their immediate managers or through the corrective action system.
All such problems are recorded, and where necessary solutions are evolved, implemented and
verified. Heads of Department are authorized to handle issues, which are within their own
control. Where interdepartmental problems are concerned, ISO department is responsible for
facilitating solutions using the Corrective and preventive Action Procedure.

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Olden Time of Malmo:

 Malmo Foods was incorporated in 1999s as organization. The Head Office & Plant is
situated at 2-km Defense road, Off Raiwind Road Lahore.
 Commercial production of dry milk powder was started in 2000. The powder was
introduced in the market in bulk form and in consumer packing.
 In 2000, it also started production of butter and ghee for its Malmo Outlets with brand
name "Malmo Butter". At start two types of powder were produced, SKIM Milk Powder
& FULL CREAM Milk Powder.
 Later in 2001, Malmo Foods launched VEGETABLE FAT FILLED Milk Powder first
time in Pakistan, which attracted many multinational companies.
 In year 2004, company lunched UHT packed milk and Desi Ghee in Tins. In order to
improve its processes and make the system more visible and to identify the shortcomings,
Malmo Foods decided to implement the concept of TQM. As an initial step, the
management opted to acquire ISO 9000 certification.
 In 2004, Malmo Foods installed UHT & Tetra Pak and launched its product with brand
name "VANIA Milk" pack size of 250ml. Malmo Foods has its distribution network in
all major cities of Punjab, NWFP and Baluchistan. Major customers of Malmo Foods
Powder Products are Asian Foods (Mayfair), Pakistan Army and many Pharmaceutical
companies. Since 2000 Malmo Foods is working on the aspect of life to provide
pasteurized milk in a healthy way. We collect best milk from its reliable resources. After
it’s careful and different checking processes 'PURE & FRESH' milk is extracted and
produced in the form of "VANIA" milk.
 In 2008 start the production of Malmo Apple, Mango, Guava and pomegranate.
 In 2012 start the production of Malmo drinking water.
 In 2015 Malmo powder milk and pasteurized milk started.
 In 2016 Malmo UHT tetra pack milk and Malmo tetra pack flavor started.
 In 2017 Malmo start the production of non dairy whipped cream and Malmo cheese
(Mozzarella and Cheddar cheese).

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Mission:
To continuously exceed our customer expectation for quality products and services” Our goal is
to offer top quality brands and innovative packaging to meet the individual needs of consumer all
over the country, whenever, wherever and however. At Malmo Foods, our research makes it
possible for everyone to enjoy better food for a better life.
Good Food is the primary source of Good Health throughout life. We strive to bring consumers
foods that are safe, of high quality and provide optimal nutrition to meet physiological needs. In
addition to nutrition, health and wellness, Malmo Foods products bring consumers the vital
ingredients of taste and pleasure.
Apart from professional skills and insight, the capacity and willingness to apply these policies
are the main criteria for progressing in the organization, regardless of origin, nationality,
religion, race, gender or age.

Vision:
Excellence in food and especially in dairy products.

Malmo Dairies Products:

Our wide range of pure dairy products has a significant impact on the improvement of health of
people. Dairy brands of Malmo Foods play a major role in the nutritional building of human
body. These instant and full of taste products help you growing faster and healthier

1. Malmo Pasteurized Milk

Pasteurized milk is dairy milk that is heated and

cooled using a simple heating process that makes
milk safe to drink before it is packaged and shipped
to grocery stores.

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2. Tea whiteners

 Vania (Liquid Tea whitener)

 Every Time (Liquid Tea Whitener)

3. Milk Powder:

 Full cream milk powder

 Instant skim milk powder
 Vegetable fat filled powder

4. Malmo Butter

5. Malmo Khoya

6. Malmo Ice Cream

 Malmo Kulfa

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 Malmo Pista
 Malmo Tooti Fruitie
 Malmo Strawberry
 Malmo Mango
 Malmo Praline
 Malmo Vanilla
 Malmo Chocolate
 Malmo Coconut
 Malmo Coffee
 Malmo Oreo

7. Malmo Cheese

 Malmo Cheddar cheese

 Malmo Mozzarella cheese

8. Malmo Drinking Water

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Certifications:
Our wide range of pure dairy products has a significant impact on the improvement of health of
people. Dairy brands of Malmo Foods play a major role in the nutritional building of human
body. These instant and full of taste products help you growing faster and healthier.These instant
and full of taste products help you growing faster and healthier.
Malmo Foods products are certified products. Some of our certificates

Milk Sampling:

Quality Sample:

This sample is taken from each portion of the tanker and is taken before receiving the Fresh milk.
On quality sample, the following tests are performed to check the quality of the milk.

Raw Milk Quality Tests:

Four types of raw milk testing.

1. Organoleptic test.

 Sensory Evaluation

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2. Quantitative tests
 L.R
 Fat%
 SNF%

Qualitative tests.
 Temp °C
 COB
 APT
 Acidity
 PH
 Salt
 Protein %
 Whey Protein %
 Aflatoxin M1

Adulteration Tests.
 Glucose
 Sugar
 Starch
 Urea
 Formalin

Raw Milk Analysis in Milk Reception Lab

1. Organoleptic test:

Principle:
To check the suitability of milk for further processing.

Materials:
Water bath, Thermometer, Beaker 500ml.

Method:
 Heat sample to 35-40°C.

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 Stir it; examine it for color, taste, and smell.

 Normal milk has a slightly sweet pleasant taste, white in color with no objectionable
odor.

Quantitative tests:

1. Lactometer Reading for SNF Calculation in Raw Milk sample:

Principle:
Determination of SNF % Total solid % in Fresh Milk sample.

Materials:
Lactometer (20°C), Measuring cylinder 250/500 ml, Thermometer, Beaker.

Method:
 Warm the sample of milk to 40°C then cool down to 20°C and then pour in cylinder.
 Gently lower the lactometer in cylinder.
 Note the reading when lactometer comes in rest. This is called lactometer reading (LR).
 Then specific gravity is calculated by the following formula
 SNF% calculate as follows

SNF% = LR/4 + (0.22xFat) +0.72

2. Determination of Fat % in Raw Milk By Gerber Method:

Principle:
Milk and Sulphur acid added to Gerber butyrometer. The butyrometer is shaken manually during
which acid digest the milk protein. A small quantity of ISO amyl alcohol is also added to
enhance fat separation during centrifugation. The butyrometer is graduated to give reading of fat
contents.

Safety Precaution:
Wear normal laboratory protective equipment’s to protect against accidental release of Sulphur
acid. Never mouth pipette the acid and amyl alcohol

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Materials:

Milk sample, butyrometer , Automatic measurer, Sulphuric acid 90-91 %, ISO-amyl alcohol,
Gerber machine 1280rpm.

Method:

Take butyrometer and add 10ml Sulphuric acid 90-91 % and gravity 1.816mg/ml at 20°C .

 Now added 10.94ml milk sample with pipette.

 Then added 1ml ISO-amyl alcohol.
 Close the stopper and shake well by wearing gloves and placed in the Gerber machine
having 1280rpm for 3 minutes and another butyrometer is also placed in front of it to
create balance.
 After 3 minutes the butyrometer is taken out and fat % is noted.
Qualitative Tests:
3. COB Test for Raw Milk sample:
Principle:
Heating of milk to boiling point.
Materials:
Milk sample, Test tube, pipette, Burner.
Method:
 Take 2ml milk in test tube with pipette.
 Now heat it on burner up to boiling point.
 If clot formation occurs then test is positive otherwise negative.

4. APT Test for Raw Milk sample:

Principle:
More or less fine coagulation in presence of alcohol of milk acidified naturally by
microorganisms.
Materials:
Milk sample, Test tube, Pipette, Apt Solution 60 %.

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Method:
 Take 2ml milk in test tube with pipette
 Add 2ml 60 % ethanol in it.
 Shake it well.
 Check precipitates.
 If precipitates are formed then test is positive otherwise negative.

5. Determination of pH in Raw Milk sample:

Materials:
Milk sample, Pipette, Beaker, pH meter, KCL3, Buffer 4 and 7, Thermometer.
Method:
 Milk sample temperature is adjusted at 20°C.
 Wash the electrode of pH meter with distilled water before use.
 Dip the electrode of pH meter in milk sample and note the pH of milk sample on pH
meter.
 KCL3 is a storage solution for pH meter electrode.

6. Determination of Acidity for Raw Milk sample:

Principle:
Formation of light pink color in the presence of indicator when titrated against the 0 .1N NaOH.
Materials:
Milk Sample, Beaker, Pipette, phenolphthalein, 0.1N NaOH.
Method:
 Take 10ml milk sample in beaker with pipette.
 Add 3-5 drops of phenolphthalein in it.
 Now titrate it against 0.1N NaOH.
 Note the end point light pink color.

Acidity % (as lactic acid) = (No. of ml used of NaOH x 0.009 100/volume of sample taken).

Acidity % = Reading/10 (Malmo Foods)

7. Determination of Protein % in Raw Milk sample:

Principle:

Milk sample is neutralized with NaOH using phenolphthalein for the release of ammonia and
back titration using formalin solution.

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Materials:
Milk sample, Titration Flask, pipette, Titration Apparatus, NaOH .1 N, dropper for 1 %
phenolphthalein, Formalin 35% 2ml.
Method:

 Take 10 ml thoroughly mixed sample in titration flask and add 3 drops of 1 %

phenolphthalein as indicator.
 Now titrate it with 0.1 N NaOH to get light pink color.
 Now add 2ml formalin solution and wait for 5 minutes.
 Titrate it again with 0.1N NaOH and note the volume V1.
 Take 2ml formalin and add 10ml distilled water in titration flask.
 Titrate with 0.1 N NaOH using phenolphthalein as indicator.
 Note the volume V2.
Calculation:
Final Reading=V1-V2
Protein % = (Final Reading x 1.94 x 100)/SNF of liquid Milk
8. Detection of Whey Protein in Raw Milk sample:
Principle:
To check the Whey Protein % of Total Protein % in liquid milk.
Materials:
Glass Beaker, Glass Cylinder, Pipette 10 ml, Pipette 2.0 ml, Thermometer, Water Bath, Filter
Paper. Formaldehyde Solution Min. 35%, N/10 NaOH Solution, Phenolphthalein Solution (as
indicator), Citric Acid 99.5 %.
Method:
 Perform Protein Test as per QCL/STM/053 and save (V1 = Final Reading X 1.94).
 Thoroughly mix the Milk Sample with the help of Thermometer.
 Take 50ml milk sample in a clean dry 100ml glass beaker.
 Heat the sample up to 60-65°C in water bath and add 0.5gm Citric Acid to get whey
content.
 Filter the whey content with the help of filter paper in a clean dry glass cylinder.

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 Take 10ml filtrate in a glass beaker and add 2 drops of Phenolphthalein indicator.
 Titrate it against N/10 NaOH solution till light pink end point.
 Add 2ml Formaldehyde in this sample and stay for 5 minutes.
 After 5 minutes, again titrate the content with N/10 NaOH till light pink colour end point
and note the reading as V2.
 Take 2ml of Formaldehyde in glass beaker and add few drops of distilled water.
 Add 2-3 drops of Phenolphthalein indicator and titrate against N/10 NaOH till light pink
end point.
 Note this reading as V3.
 Calculate the Whey Protein % as per given formula:
 Final Reading = V2 – V3
Whey Protein % (of Total Protein %) = (Final Reading X 1.94 X 100) / 1
9. Determination of Salt in Raw Milk sample:

Principle:
Determination of (Nacl) Salt % in raw Milk sample.
Materials:
Burette, Pipette, Dropper Bottle, Beaker.
Method:
 Take 9ml of well mixed sample in a 100ml glass beaker.
 Add 3-4 drops of Potassium Chromate indicator.
 Tare the burette reading before titration and make sure that it is at “0”.
 Titrate the sample against 0.1N Silver Nitrate (AgNO3) solution.
 Stop titration when light brown colour appears.
 Note the reading of AgNO3 used from burette.
 Calculate the Salt percentage as follows:
Salt%= readingx0.065x8.52 / SNF %

10. Aflatoxin M1 Detection Test for Raw Milk Sample:

Principle:
To check the presence of aflatoxin in raw milk sample.
Material:

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Aflatoxin M1 detection, Automatic pipette 200ml, Incubator, Pipette Tips.

Method:
 Turn on incubator and wait until the temperature has stabilized at 40C.
 Get the kit from refrigerator and allow the test tube to warm up to room temperature.
 Take required no of microwells and dipstick from test tube.
 Thoroughly mix the sample to be homogenous before testing.
 Pipette 200ml milk sample into regent microwell and mix well by pipetting up and down
5-10 times.
 Incubate the sample microwell for 3-minutes at 40- 2 ºC.
 Insert the dipstick into microwell after first incubation. Incubate for 4-minutes at 40-2 ºC.
 After 4-minutes take out dipstick from micro well and remove the sample pad at lower
end.
 If there is normal control line (C) at the top, compare the colour intensity of Test Line (T)
and Control Line (C) and interpret the result from given chart.
Adulteration Tests:
1. Detection of Glucose in Raw Milk sample:
Principle:
To check the presence of Glucose in raw milk.
Materials:
Milk sample, Test tube, pipette, Barford’s reagent, water bath 100 ºC,stop watch.
Method:
 Take 5ml of milk in test tube with the help of pipette.
 Now add 5ml Barford’s reagent.
 Mix it well and place in water bath 100 ºC for six minutes.
 And note the result by comparing the color change with evaluation chart.
 If color is greenish then it is positive and if color is blue then negative.
2. Detection of Sugar in Raw Milk sample:
Principle:
To detect the adulteration of sugar in raw milk sample.
Materials:

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Pipette10ml, water bath 100 , Thermometer, Alpha naphthol, HCL 37%, pipette1ml, stop watch.
Method:
 Take 2 drops of milk in test tube with the help of pipette.
 Add 3-4 drop of alpha naphthol 10% as indicator..
 Add 3ml 37% HCL in test tube.
 Mix it well and place it in water bath 100 ºC for 10 seconds.
 Let the test tube contents to be cooled down.
 Deep violet color ring after 5-minutes indicates the presence of sugar.
3. Detection of Starch in Raw Milk sample:
Principle:
Color of starch in milk by mean of iodine. It is added to increase density.
Materials:
Milk sample, Test tube, pipette, Iodine solution,spirit lamp,petri dish.
Method:
 Take 3ml 3-4 of well mixed sample in test tube.
 Warm the sample to boiling point over spirit lamp flame.
 Pour the boiled sample gently in a glass petri dish.
 Add 4-5 drops of iodine solution and mixed the contents.
 Dark blue color or black particles indicates the presence of sugar in raw milk sample.
4.Detection of Urea in Raw Milk sample:

Principle:
Formation of pink coloration of the phenol red indicator due to reaction of urea with urease
enzyme in the solution.
Materials:
Milk sample, test tube, pipette, urease solution, phenol red indicator, water bath 40 ºC.
Method:
 Take 2ml milk in test tube with pipette.
 Now add 2ml urease solution (2g urease powder, 3g dipottasium hydrogen
phosphate andmake the volume up to 1000ml) in test tube.
 Place the test tube for 10-minutes and observe the colour change.

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 Light green colour indicate the adulteration of urea in raw milk sample.
5. Detection of Formalin in Raw Milk sample:
Principle:
Sulphur acid containing traces of ferric chloride give purple color with formalin present in
sample.
Materials:
Milk sample, Test tube, pipette, 90 % Sulphur acid with traces of ferric chloride.
Method:
 Take 10ml of thoroughly mixed sample in clean dry test tube
 Add 0.5ml of ferric chloride in test tube and mixed the contents.
 Add 5ml conc.H2SO4 carefully down the side of test tube in such way that it forms a
separate layer at bottom without mixing with milk.
 Development of violet color ring between milk and acid indicates the presence of
Formaldehyde.
Raw Milk Tests:
Parameters Results
Organoleptic Clean,Pleasant and no off taste or flavour
SNF% 7.902%
Fat% 4.1%
COB -ve
APT -ve
pH 6.6
Acidity 1.08%
Protein 36.8%
Whey Protein 0.815%
Salt 0.29
Aflatoxin M1 -ve
Glucose -ve
Sugar -ve
Starch -ve

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Urea -ve
Formalin -ve

Powder Milk Tests:

There are following test of powder milk:
 Organoleptic Evaluation.
 Acidity Determination.
 PH Determination
 Fat Determination.
 Moisture %.
 Bulk Density.
 Wet Ability.
 Protein % Test.
 Solubility Index.
1. Organoleptic Evaluation of Powder Milk:
Principle:
To check powder milk with respect to sensory evaluation.
Material:
Glass beaker 250ml, Weighing balance, Water bath, Thermometer.

Method:
 Take 80ml distilled water in 250 ml glass beaker.
 Weigh 10g in case of Skimmed Milk Powder and 13g for Full Cream Powder.
 Add powder to distilled water and thoroughly mix the contents.
 Make volume up to 100ml with distilled water and allowed the sample to stand for on
hour.
 Heat the sample 25C in water bath and examine for taste, color and odour.
2.Acidity Determination of Powder Milk:
Principle:

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To determine the titrate able acidity of milk powder.

Material:
Glass beaker , Weighing balance, Burette 25ml, Glass rod, Pipette 10ml.
Method:
 Take 80ml distilled water in a 250ml glass beaker with the help of 100ml glass cylinder
 Weigh 10g powder sample for skimmed milk powder and 13g of full cream powder.
 Thoroughly mix the sample to distilled water and make volume 100ml with distilled
water.
 Take 17.6 ml sample and allow stamding for half an hour and then stir gently.
 Add 3-4 drops of Phenopthaline indicator and titrate against 0.1N NaOH solution till light
Pink colour persist for 30 seconds.
 Note the burette reading and calculate the titrate able acidity as follow:
Acidity%(lactic acid)= Burette Reading/20
3.PH Determination of Powder Milk:
Principle:
To judge the keeping quality of dry milk or estimate the intensity of acidity of dry
milk
Material:
pH meter, Thermometer, Glass beaker 250ml.
Method:
 Weigh 10g powder for SMP and IFCMP/VFFMP in 250ml glass beaker and make
volume 100ml with distilled water.
 Allow the sample to stand for about 30-minutes and mix well with stirrer.
 Adjust the temperature of sample at 20C.
 Dip the ph electrode in sample solution.
 Wait till the reading become stable.
 Note PH reading from ph meter display.
 Ph range of acceptable powder milk is between 6.65-7.00.
2. Fat Determination of Powder Milk:

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Principle:
Determination of fat in powder milk sample.
Material:
Butyrometer(0-35%), Weighing balance, Water bath, Thermometer, Butyrometer stopper,
Butyrometer stand, Centrifuge machine 11rpm, Auto measure
Method:
 Pour 10ml H2SO4 into butyrometer with help of auto measure.
 Add 2ml of distilled water.
 Weigh 2.5g of powder sample and pour into butyrometer.
 Add 2ml of Iso Amyl Alcohol; stopper the butyrometer and well mix mix the contents by
shaking.
 Place the butyrometer in Centrifuge machine for 10-minutes at 65C.
 After 10-minutes, take out the butyrometer and read the fat column.
 Note down the column reading as fat%.

5.Moisture Analysis of Powder Milk:

Principle:
To determine the moisture % in powder milk using Moisture Analyzer.
Material:
Moisture Analyzer, Aluminium Boat.
Method:
 Power on the moisture analyzer; set the temperature at 110c and timer at 6-minutes.
 Take 2.50-2.70 grams of powder milk in aluminium boat placed in moisture analyzer.
 Evenly distribute the sample over the boat for quick evaporation.
 Close the moisture analyzer lid and press the start button.
 After specified time, screen will display the moisture%.
 Note the reading directly from screen as moisture%.

6.Bulk Density of Powder Milk:

Principle:

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To determine the bulk density of powder milk.

Material:
Jordan apparatus, Weighing balance, Spatula
Method:
 Weight the Jordan Appratus cylinder without top.
 Put the top on cylinder and fill up to the rim powder using a spoon.
 Tap the cylinder 100-times; remove the top and scrap off powder with help of a spatula.
 Weigh the cylinder; the weight of powder indicate powder’s bulk density.
 Powder Bulk Density= Weight of the powder /100.
 Calculate the results to two Decimal Points.
7.Wet Ability Test for Powder Milk:
Principle:
To check the ability of powder milk to be dissolved in water.
Material:
Weighing balance, Stop watch. Glass beaker 250ml Spoon, Water bath,Wet ability apparatus.
Method:
 Take 150ml tap-water having temperature 30-35 in glass beaker.
 Close the top of beaker with a piece of paper and adjust in the wet ability apparatus.
 Weight 10g of powder milk sample and pour in top portion of apparatus.
 Remove the piece of paper between powder and glass beaker and allow the powder to
free fall in the water.
 Note the time of powder to be completely wet in water.
 Express the results in seconds.
8. Protein % Test of Powder Milk:
Principle:
To check the protein% of powder milk.
Material:
Glass beaker,Glass cylinder, Pipette 10ml, Thermometer, Weigh balance.

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Method:
 Take approx. 80 ml distilled water in 250 ml glass cylinder.
 Tare the weight balance and weight powder milk as follow:
 10 gm for ISMP/SMP
 13 gm for IFCMP/VFFMP
 Pour the weighed powder in distilled water cylinder and mix well with thermometer.
 Make the volume exactly 100ml by adding distilled water and mix thoroughly.
 Stay for 30-minutes so that the foam in sample to be removed.
 Take 2ml sample in dry clean glass beaker with the help of 10ml pipette.
 Add 2-3 drops of Phenolphthaline indicator in the sample and titrate it against N/NaOH
till light pink end point.
 Add 2ml Formaldehyde in titrated sample and stay for 5-minutes.
 Again titrate with N/10 NaOH till light pink end point and note the reading as V1.
 Take 2ml Formaldehyde in glass beaker and few drops of distilled water in it.
 Titrate it against N/10 NaOH till light pink end point and note the reading as V2.
 Calculate the protein% as per given formula:
Final Reading = V1-V2
Protein% = (Final Reading x1.94) x 100

Parameters Results
Organoleptic Clean, Pleseant and no off flavor
Acidity% 0.2%
pH 7.1
Fat% 3.1%
Moisture% 2.49%
Bulk Density 0.75
Wet Ability 6.5 sec
Protein 40.95

Water Tests:

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There are following tests which performed on water:

 PH Determination.
 Total Hardness.
 Calcium and Magnesium Determination.
 Chloride Estimation

1. PH Determination of Water:
Principle:
To estimate the acidity or alkalinity in feed water or boiler water.
Material:
Ph meter.
Method:
 Adjust the sample temperature at 20C.
 Immerse the ph meter electrode in sample and wait till the reading becomes stable.
 Note the ph reading from PH meter display.

2.Total Hardness of Water:

Principle:
To detect the quality of feed water to boiler as a safety measure.
Material:
Glass Beaker 100ml, Pipette 1.0 ml, Burette, Glass Cylinder 25ml.
Method:
 Take 25 ml water sample in a 100 ml glass beaker.
 Add 0.1 ml Ammonia Buffer Solution in it and add 2-3 drops Erichrom Black-T as
indicator.
 Titrate it against EDTA 0.1N solution till the light blue end point.
 Calculate the total hardness as:
Total Hardness (ppm) = Burette Reading x 40

3. Chloride Estimation of Water:

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Principle:
To determine the presence of Chloride in drinking water.
Material:
Glass Beaker 100ml, Glass Cylinder 25ml, Pipette 10ml, Burette.
Method:
 Take 25 ml of water sample in a glass beaker.
 Add few drops of Potassium Chromate indicator.
 Titrate against 0.1N Silver Nitrate solution till Brick Red end point.
 Calculate Chloride content as follows:
Chloride (ppm) = Burette Reading x 40

4. Calcium and Magnesium Determination of Water:

Principle:
To determine the calcium and magnesium hardness in drinking water.
Material:
Glass Beaker 100ml, Glass Cylinder 25ml, Pipette 10ml Burette.
Method:
 Take 25 ml water sample in a 100 ml glass beaker.
 Add 2-3 drops of Ammonia Buffer Solution in it and then add 2-3 drops of Murexide
as indicator.
 Titrate it against EDTA 0.1N solution till the light purple end point.
 Calculate the Calcium and Magnesium hardness as:
Calcium Hardness (ppm) = Burette Reading x 16.04
Magnesuim Hardness (ppm) = (Total Hardness Reading – Ca Hardness Reading) x
9.78
Parameters Results
pH 6.7
Total Hardness 116ppm

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Chloride Estimation 56ppm

Calcium and Magnesium 6.846ppm

Production or Processing Plants of Malmo Foods:

Dairy section
Milk is the complete diet for human being. It is considered to be as the nature’s perfect food. In
Pakistan, cows and buffaloes are the prime sources of milk. Milk is a complex emulsion of fat
and a colloidal dispersion of protein, together with milk sugar in to solution. It is obtained in
from the lactating female through natural process their udders and teats, only when they give
birth to their young ones.
Dairy department deals with the reception, processing & production of UHT milk and various
milk products.
I visited following sections during our internship:
 Pasteurization Section
 Evaporator
 Milk Powder Plant
 Ice Cream Section
 Cheese Section
 Butter Section
 Khoya Section
 Desi Ghee Section
 Ro Water Section
 CIP Section
 Bakery Section

Pasteurization Section
The founder of this procedure is Louis Pasteur; in which heat treatment is given to the milk in
order to inactivate the enzymes and destroy the pathogenic microorganisms & it also produce
whitening in the milk. The shelf life of the milk is increased up to 7-8 days after pasteurization.
Capacity of pasteurization plant is 15000L per hour.

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The following steps take place in the process of pasteurization:

1: Reception of Milk:
Milk is received from a silo and is filtered by passing through a centrifugal pumps.

2: Plate Heat Exchanger:

Then, milk is entered in PHE here milk is chilled by passing out of chill water from plate pipes.

3: Balancing Tank:
Milk is collected in balancing tank which controls the quantity of incoming milk by a valve and
maintain the milk level as needed by the process.

4: Regeneration 1:
From balance tank milk goes to regeneration 1, where the temperature of the milk is raised up to
40-45ºC by regeneration method. In regeneration No1 the milk and the hot milk coming after
pasteurization has counter flow.

5: Regeneration 2:
Then milk goes to regeneration 2. It is also a part of pate heat exchanger (PHE) in which milk is
heated up to 65-70ºC.

6: Separator:
From regeneration 2 milk goes to separator that will separate the extra butterfat from the milk in
the form of cream and it will also remove the unwanted material I the milk (Sludge). Separator
works at 6000-7000 rpm & it has porous stacked plates. Cream is passed towards cream
pasteurizer.
Due to centrifugal force, fat particles having less density are separated from the milk. Impurities
are also separated through the centrifugal action, as they settled down at the bottom, from where
these are disposed off.

7: Deodorizer/Degasser:
From separator milk goes to deodorizer. As the name indicates it deodorize the bad smell of
milk. It is steel tank (5 feet long) and divided into two parts by a thin steel plate. The lower
portion of deodorizer contains cold plate having chilled water line, which cools the central plate.
Milk falls on the cold surface; the bad odor vapors rise upward and these are sucked out by a
vacuum pump and released out after condensation along with water.

8: Homogenizer:

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From deodorizer milk goes to homogenizer in which milk is passed through nozzle at high
pressure of 120-150 bar as a result fat globules are converted into smaller particles (1 µm).

9: Heating section:
In the heating section temperature of milk is increased to 85-90ºC with help of hot water.

10: Flow Diversion Valve:

If temperature of milk is less than 85ºC, it will not go towards holding tubes, it is delivered back
to balance tank by flow diversion valve for reproducing.

11: Holding Tubes:

Here milk stays for 15 sec at 85-90ºC, so that enzymes like phosphates, peroxidase, lipase etc.
are inactivated and microbes are killed.

12: Regeneration 2:
Pasteurized milk moves back in regeneration 2 to warm the cold milk of balance tank. So in this
way energy is conserved. Here temperature of milk drops to 55-60ºC.

13: Regeneration No 1:
Pasteurized milk heated the incoming cool milk to save the energy. Here the temperature of milk
drops 35-40ºC.

14: Cooling section:

In cooling section, ice water of 2ºC is circulated so temperature of milk drop to 7 to 8ºC.

15: Storage Tanks:

From cooling section, milk is passed towards storage tanks here temperature of milk is
maintained at 8ºC for 12 hours. After 12 hours, 1 point of temperature is increased.

Flow Diagram of Pasteurization Plant

Reception of Milk

Plate Heat Exchanger

(PHE)

Balance Tank

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Regeneration 1

Regeneration 2

Cream Separator

Degasser

Homogenizer

Pasteurization/Heating

Holding Tubes

Regeneration 2

Regeneration 1

Cooling Section

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Storage Tanks
Milk Powder Plants:
1. Evaporation Section:
Powder milk is a manufactured dairy product made by evaporating milk to dryness. One purpose
of drying milk is to preserve it, milk powder has a far longer shelf life than liquid milk and does
not need to be refrigerated due to its low moisture content.
Another purpose is to reduce its bulk for economy of transpiration. Powdered milk and dairy
products include such items as: Skimmed Powder Milk, Full Fat Powder Milk, Vegetable Fat
Powder Milk.
Triple effect and Multi stage evaporator is used for drying of milk.
1: Reception of Milk:
Pasteurized Milk is received from Pasteurization section. The milk received in balancing tank
should fulfill following requirements:
Temperature = 10ºC
Brix = 8-10
LR = 26.5
SNF = 8.0-8.5%
Total Solids:
 Skimmed Milk = 95%
 Full Fat Milk = 96.7%
2: Condenser:
From balancing yank, milk is passed towards condenser. Here, milk is heated by hot vapors and
temperature of milk is raised to 25ºC and vacuum is 650-750 mm/Hg.
3: Pre-heater:
Pre-heater is heated by steam vapors. The temperature of pre-heater is 75ºC.
4: Plate Heat Exchanger:
In PHE temperature is increased, milk is heated up to 75ºC. Steam vapors cause increase in
temperature. Here, most of the moisture of milk is removed and brix of milk is increased.
5: 1st Body:
In 1st body, temperature is 73ºC. 1st body is heated by pre-heater of 1st body that cause heat by
steam vapors from PHE. Here, vacuum is at 5500 mm/Hg and brix of milk is reached to 15-20.
6: 2nd Body:

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Vapors from 1st body heat the pre-heater of 2nd body. As, steams vapours are circulating again
and again so temperature of 2nd body is 63ºC and vacuum is 6400 mm/Hg. due to high vacuum
formation brix of milk is increased to a range of 25-35.
7: 3rd Body:
Third body is heated like first two bodies. Here, vacuum is increased at 7400 mm/Hg and
temperature is 58ºC. Brix of milk is reached to 45-50, that is basically brix of condensed milk.
Here, condensed milk is formed.
The vapors of 3rd body go in condenser and then drained out.
 Condensed milk is formed to lower the water level of milk because milk with high water
content can't be powdered. This condensed milk is then transferred to powder plant for
drying.
The brix of condensed milk used in Malmo is from 48 to 53.

Flow Diagram of Evaporator Plant:

Balancing

Condenser

Preheater

PHE

1st Body

2nd Body

3rd Body

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2.Powder Section:
Powder Plant
In powder section, milk is dried and converted into instant granules powder. Powder milk is of
three types:
1. Skimmed milk powder
2. Full Fat milk powder
3. Vegetable Fat milk powder

1: Condensed Milk Trolleys:

Condensed milk trolleys are received from evaporator normally at 45ºC. This milk is used for
drying process.
2: Feed Pump:
Feed pump, pumps the milk towards pre-heater.
3: Pre-heater:
In pre-heater, the condensed milk is heated up to 50-55ºC. If the temperature of milk is lower
than steam is injected in pre-heater to raise the temperature.
4: Filter:
A filter is installed to remove impurities or outer particles from condense milk.
5: Nozzles:
Milk is entered in nozzles by a high pressure pump which contains pressure of 200-220 bar.
Three nozzles are here that shower the condensed milk up to 100ºC into chamber drier. Lacithin
is added for volatability.
6: Chamber Drier:
In chamber drier, temperature is upto 100ºC. here, milk is dried and converted into powder form.
Grain particles of powder settle down in bottom of chamber while fine particle are pushed into
vibro cyclone by hot air circulation then exhausted in chamber and by showering of condensed
milk again converted into instant. Temperature of air is 189ºC and velocity of air is 14.5 m/sec.
Inside chamber vacuum is set at -5 to -10 mm/Hg.
Chamber capacity is 800kg/h.
7: Fluidizer beds:
From chamber powder is hambered into fluidizer beds. Hambering is done to pass instant
powder grains into beds and to prevent sticking of powder.
In fluidizer bed, hot air is injected to remove the moisture of powder milk. Moisture content of
skim milk is lowered to 3.4% and for full cream milk moisture content is 2-3%.

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Cool air is injected to fluidizer bed to normalize the temperature of powder. outlet temperature of
powder is 30-40ºC. It is also storage temperature of powder milk.

Flow Diagram of Powder Milk:

Condense Milk Trolleys

Pre-heater

Filter

Nozzels

Chamber Dryier

Fluidizer Bed Vibro Cyclone

Hot Air Inlet

Cool Air Inlet

Packaging

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Ice-cream section:

Malmo ice cream production:

In Malmo following type of flavor of ice cream production take

place:

 Praline Ice cream

 Strawberry Ice cream
 Kulfa Ice cream
 Mango Ice cream
 Pista Ice cream
 Vanilla Ice cream
 Tuttie fruity Ice cream
 Oreo Ice cream
 Coconut Ice cream

Following steps which are involved in the ice crem section:

Pasteurization:
Pasteurization of milk is done at 85ºC. Pasteurization tank is a double jacketed tank and hot
water is circulated in double jackets to pasteurize the milk.
Mixing:
All the ingredients mix together. Powdered milk is added other ingredients include water (60ºC)
sugar, fresh cream (40 percent fat), Khoya, chocolate, Kulfa, coco powder and glucose added
according to taste. Mixer temp should 80ºC.
Homogenization:

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Homogenization done at 100 to 150 bar pressure. It takes 30 minutes for 500 kg mix. In
homogenization tank agitator attached helps in homogenization. Purpose is to get well mixed
paste.
PHE:
Temperature of mixture is lowered to 22ºC by circulating cold water.
Aging tank:
Mix is shifted in aging tank. Aging takes 6 hours. Chiller tank is connected with it for cooling
purpose. This is a double jacketed tank in which chill water of 0ºC is circulated and temperature
of mix is lowered to 5-8ºC.
After aging flavors added. Mixed well so that no bitter taste produced.
Freezer:
Mix is shifted in continuous freezer at-4 to -7 ºC. Temperature. Here, 100% cool air is provided
that lowers the temp to -8ºC.
Dasher:
Dasher has blades that cut ice- cream and air is incorporated through compressor that produces
softness in it. Cooling tower is attached with freezer in which cool water in and warm out.
Fruit feeder:
Fruits are added according to flavor and taste. Almond crunch, chocolate and coco powder are
added at this stage. Different nuts and pistachio also added.
Packaging:
Packaging done according to requirement i.e. in cups, packs, boxes.
Blast room:
Ice cream is kept in blast room at -30ºC for 8 hours.
Cold storage:
Packed ice cream is stored in cold storage at -20 to -22ºC.

Flow Diagram of Ice cream

Pasteurization

Mixing

Homogenization

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Aging Tank

Freezer

Dasher

Fruit Feeder

Packaging

Blast Room

Cold Storage

Cheese Section:

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Cheese:
Cheese is a dairy product derived from milk that is produced in a wide range of flavors, textures,
and forms by coagulation of the milk protein casein. It comprises proteins and fat from milk,
usually the milk of cows, buffalo, goats, or sheep. During production, the milk is usually
acidified, and adding the enzyme rennet causes coagulation. The solids are separated and pressed
into final form. Some cheeses have molds the outer layer, or throughout. Most cheeses melt at
cooking temperature.
Cheese is a good source of calcium and protein, but it can also be high in saturated fats and
sodium.
Cheese types:
a) Mozrella cheese
b) Cheddar cheese
Mozrella cheese process:
Pasteurization:
For cheese formation, raw milk is taken on the base of protein ratio. Then Pasteurization is done
to remove the extra fat. Pasteurization is done at 50 ºC then chill at 10-12 ºC
1. Cheese vat:
Then Pasteurization milk is pure into a vat (Its capacity is 2000L) which is heated at 35 ºC. It is
double jacket contain water steam circulates in the double jacket.
2. Milk Culturing and Clotting:

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Culture is added at 26-27ºC for Mozzarella and 30-35ºC for Cheddar cheese. Then milk is
kept for rest for 15 min.
After 15min Rennet is added to milk and kept rest for 50-60min for curd production.
3. Cutting and separation:
When curd are formed the curds are cut into pieces to separate the whey from curds.
4. Cooking and Stirring:
The cooking and stirring process continues until the curds have reached the preferred
temperature (40-41ºC) and hardness rise the 1ºC temp in every 5 mint. Once this is complete,
the whey is drained away, leaving the solidified curd.
5. Cheddaring:
Cut into blocked and changed the side (to remove excess remaining water from the blocks by
changing the sides).it takes 1 hour to complete the process.

Objective
 To remove the whey completely.
 Culture growth is good.
 Holes formed un curd are removed.
6. Milling:
When whey is removed completely milling is done. Salt added in curd. About 2 to 2.5 kg salt
is added in 1 vat.
7. Pressing:
Mold pressing is done. Overnight pressing with 3 to 4 bar pressure. To remove whey completely
otherwise mold growth takes place that ultimately produces bitter taste during aging process.
Muslin cloth added with blocks so that molded cheese doesn't flow outside.
8. Aging:
Muslin cloth removed and polythene bags wrapped around the blocks. Then it place in cold
storage for 24 hours at 3 to 4ºC its purpose is to dry the surface after pressing. After that
potassium-sorbate is sprayed (10 percent solution is prepared to spray) then it is packed again
place in cold storage for 24 hours so surface become compact and dry.
9. Ripening:
Ripening process is done for minimum 2 months i.e. it is placed in cold storage for 2 months. Its
purpose is to produce the flavor, cheesy aroma and required texture. 20kg polythene bags are

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used to wrap the blocks. During ripening culture growth takes place, protein structure breakdown
and amino-acids units are formed. The breakdown produces softness.
10. Molding, packaging and storage:
Melted cheese is put in mold trays then to cold storage overnight for hardening purpose. Then it
is packed in polythene bags and it is done under vacuum. Again, it is stored in cold storage.
Storage temp. Is about -18ºC.

Flow Diagram of Cheese Processing

Pasteurization

Milk culturing ,clotting

Cutting and separation

Cooking and stirring

Cheddaring

Milling

Pressing

Aging

Ripening

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Molding packaging

Butter section:
1. Reception of cream:
Pasteurized cream is received from silo. This cream is received from pipes.
2. Continuous Butter Making Machine:
The cream is received in a balancing tank. From balancing tank cream is entered in butter
making machine. A gear box is installed in continuous butter making machine which controls
and runs all the system i.e. temperature, pressure and flow of cream.
3. Churning:
Here churning process is started. Churning is done at 1100 rpm. Capacity of churner is 2000
kg/h.
4. Batch Churn:
In batch churn cream is received and centrifugation is done 800kg cream is centrifuged at one
time.
 In batch churn hot and pasteurized cream can be used .
 In continuous butter making machine only pasteurized cream is used.
5. Packaging:
Butter is packaged in plastic and polythene bags and also in tin cans.

Flow diagram of Butter processing

Reception of cream

CBMM

Churning

Batch Churn

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Packaging

Khoya section:
For production of Khoya milk is received on Fat and LR base. Milk is received in raw form i.e.
no pasteurized milk. It is cooled in chiller before use. Steel pans used to heat the milk on very
high temp. Milk becomes concentrated on this high temp. Processed Khoya is layered in trays to
cool down at ambient temp. And then packed in polythene bags and stored in cool storage at -18
ºC.
Flow diagram of khoya processing

Raw Milk

Panning

Heating(160-150ºC)

Continuous stirring

Khoya

Cooling &Packaging

Cold Storage

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Desi Ghee Section:

Ghee is clarified milk fat prepared chiefly from cow or buffalo milk.
The term clarifies means to make clear a liquid or something liquefied
bye remaining unwanted solid matter or impurities.
Taste aroma and texture:
The taste of ghee is surprisingly different from that of butter its aroma is
best described as nutty and it has the unique property of carrying and
enhancing the flavor of practically any that one briefly fries with it.
The texture colour or taste of ghee depends on the source of milk from
which the butter was made and extent of boiling.
Ghee manufacturing process:
 Fill ghee melters to about 800-900kgs with butter.
 Open steam valve of melter's pressure at 1-1.5 bar .steam button for 10 hours.
 Remove lassie and sludge from the bottom of the melters.
 If moisture is 0.3%, then close the steam valve.
 Open raw water valve of the melters to cool down the ghee to room temperature.
 Filter out ghee carefully into clean and dry plastic cans and covers the lids.
 Then pack of ghee in 1kg tin and pouches.
 At the end, CIP occurs.

Flow diagram of Desi Ghee processing

Reception of Butter

Steam 200ºC for 30mins

30-45 mins stay time

Melted Butter

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Butter milk drained out

Steam 200 ºCfor2-3hour

Ghee obtained 99.5% Packaging& storage-20

Water section:
RO Water Filtration;
1. Raw water source:
Underground water is source of this water filtration system. Turbine and pump used to pull water
in tank. Then it moves to further for filtration purpose
2. Filter Assembly:
Cartridge water assembly use to filter pump. Three filters with 5µ size are used it. Purpose is to
remove suspended particles and undissolved particles
3. Sand Filter:
Sand layers of different partial size are used in this filter. Granular gypsum is used in layers
through which water moves 4-5 layers of sands are used. Top and bottom layers of large size to
move water
4. Activated Carbon Filter:
Activated carbon is used. It helps to remove odor and unpleasant smell
5. Filter Assembly:
Again, water pass out through another filter assembly. Here 5 filter with 1-3 µ size are used.
Here ultra filtration done
6. High pressure pump:
Water is passed through high pressure pump 2-3 bar pressure. The inlet and out let pressure is
same I.e. Water inter in and leave with same pressure. Greater than pressure less will be the
TDS. Then it will inject water in RO

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7. Anti-scalding:
Anti-scale dosing is done, and its purpose is to remove undissolved minerals i.e. No sticking of
minerals with walls of filters. Water after passing out this stage is called as permeate water
8. Pneumatic dosing:
Mineral dosing its done. Ozone is also used for dosing along minerals. Mostly Calcium, Mg, and
Sodium are added as minerals. Minerals dosing is done to balance minerals level in water.
Moreover, ozone dosing done. Ozone acts as antimicrobial. It takes 2.5 to 3 hour stop complete
the ozone reaction with water
9. Storage Tank:
Water is stored in storage tank. Here water stayed for 13 minutes until the minerals and ozone
get dissolved in water completely. Then water is passed to final storage tank through feed pump
with 1.5 to 2 bar pressure
10.U.V Lamps:
Water pass through U. V lamp assembly. After passing through this all the microbes killed
11.Auto Washer and Filling:
Bottles are washed inside and outside with hot water pressure. Then filling is done. Balance tank
check the level a filled water in bottles then bottles is passed through conveyer. Cap is pressed
and then bottle passed through U.V screen then sealed.

Flow Diagram of Water

Raw water line Raw water storage tank

Sand filter Water assembly

Activated carbon filter

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Pressure vessel

Filter assembly 1-3 µ

Pneumatic dosing

Anti Scalding

Storage tank

U.V lamps

Auto washer&filling

Sealing of bottels

Storage

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CIP SECTION (Cleaning in place):

Definition:
CIP is removal of milk particles and lowering the microbial load in the production line & in the
raw milk tanker by using various types of cleaning agent (acid, base & water).
Functions of various cleaning agents in CIP;
 Lye for removal of fat residues.
 Acid for the removal of protein matter
 Hot water for the removal of residues and salt
 Acid and hot water also used for lowering microbial load.
Concentrations:
Concentration of acid and lye used for the CIP is:
 Lye (NaOH) = 1.7-2.2% at 80 -85℃
 Acid (HNO3) =1-1.5% at 70-75℃
 Water at 80-85℃
CIP Steps:
 Water rinsing
 Alkali rinsing
 Acid rinsing
Types:
Two types of CIP are done
 Short CIP (40min)
 Long CIP (70min)
Short CIP:
 Milk is drained out of tanker or the pipelines and then it is washed with water for 10 min.
 After this lye (NaOH) solution of1.7-2.2 % at temperature of 80- 85℃ is circulated in the
tank or lines for 10 minutes.
 Again, tanker is washed with water for 5 min.

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 Then Nitric acid having a concentration of 1-1.5% at the temperature 70-75℃ of is

circulated in the tank or lines for 10 minutes.
Long CIP:
 Milk is drained out of tanker or the pipeline and then it is washed with water for 5
minutes.
 After this lye (NaOH) solution of 1.7-2.2% at temperature of 80- 85℃ is circulated in the
tank or lines for 15 minutes.
 Again, tanker is washed with water for 10 min.
 Then Nitric acid having a concentration of 1-1.5% at the temperature 70-75℃ of is
circulated in the tank or lines for 15 minutes.
 Again, tanker is washed with hot water at 80 -85℃ for 10 minutes. H2O2 is also
circulating for 10 minutes in case of ATS tank.

Bakery Section:
Bakery is an establishment that produces and sells flour-based food baked in an oven such as
bread, cookies, cakes, donuts, pastries, and pies. Some retail bakeries are also categorized as
cafés, serving coffee and tea to customers who wish to consume the baked goods on the
premises. Confectionery items are also made in most bakeries throughout the world.

Baked goods have been around for thousands of years. The art of baking
was developed early during the Roman Empire. It was a highly famous art
as Roman citizens loved baked goods and demanded them frequently for
important occasions such as feasts and weddings. Because of the fame of
the art of baking, around 300 BC, baking was introduced as an occupation
and respectable profession for Romans. Bakers began to prepare bread at
home in an oven, using mills to grind grain into flour for their breads. The
demand for baked goods persisted, and the first bakers' guild was
established in 168 BC in Rome.
Following are bakery products of Malmo:
 Bread
 Sponges
 Cakes
 Biscuits
 Cake Russ
 Sweets

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 Pizza
 Sandwiches

Bread:

Bread is a staple food prepared from a dough of flour (usually wheat) and water, usually by
baking. Throughout recorded history and around the world, it has been an important part of many
cultures' diet.
Bread may be leavened by naturally occurring microbes (e.g. sourdough),
chemicals (e.g. baking soda), industrially produced yeast, or high-
pressure aeration, which creates the gas bubbles that fluff up bread. In
many countries, commercial bread often contains additives to improve
flavor, texture, color, shelf life, nutrition, and ease of production. Bread is
also made from the flour of other wheat species. Non-wheat cereals
including rye, barley, maize (corn), oats, sorghum, millet and rice have been used to make bread,
but, with the exception of rye, usually in combination with wheat flour as they have less gluten.

Methods of processing dough:

1. Straight dough process
2. Sourdough process
3. Chorleywood bread process
4. Sponge and dough process

Sponges:
Sponge cake is a light cake made with egg whites, flour and sugar, sometimes leavened with
baking powder. Sponge cakes, leavened with beaten eggs. The sponge cake is thought to be one
The basic whisked sponge cake does not contain any fat. It is made by whisking egg whites and
caster sugar and gently folding in flour. The process of whisking egg whites incorporates air
bubbles to create a foam by agitating the protein albumen to create a partially coagulated
membrane, making the egg whites stiffer and increasing their volume. This type of cake, also
called foam cake, depends on aeration of eggs and heat to rise. Some types of sponge are baked
in ungreased pans to improve the cake's rise by allowing the batter to adhere and climb the sides
of the pan. To maintain the moisture of the cake it is sometimes made with potato flour.
Variations on the basic sponge sometimes add butter or egg yolks to make the cake moister.

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Biscuits:
A biscuit is a flour-based baked and shaped food product. In most countries biscuits are typically
hard, flat, and unleavened. They are usually sweet and may be made with sugar, chocolate, icing,
jam, ginger, or cinnamon. They can also be savoury, similar to crackers.
Types of biscuit include sandwich biscuits, digestive biscuits, ginger biscuits,
shortbread biscuits, chocolate chip cookies, chocolate-coated marshmallow
treats, Anzac biscuits, biscotti, and speculaas.
The biscuit method is the process of blending butter (or a fat of some kind)
into flour so that it provides a flaky texture. Usually, this is done by
combining flour and cold butter that has been broken down into pieces around the size of a pea,
and then folding in a liquid to combine it all together.

Cake Russ:
A rusk is a hard, dry biscuit or a twice-baked bread. In some cultures, rusk is
made of cake, rather than bread. this is sometimes referred to as cake rusk. It is
usually (but not always) made from stale bread and buns. Some bakeries use
their stale buns and bread for making rusks.

Cake:
Cake is a form of sweet food made from flour, sugar, and other ingredients, which is usually
baked. In their oldest forms, cakes were modifications of bread.
The most commonly used cake ingredients include flour, sugar, eggs, butter or oil or margarine,
a liquid, and a leavening agent, such as baking soda or baking powder.
Common additional ingredients and flavourings include dried, candied, or
fresh fruit, nuts, cocoa, and extracts such as vanilla, with numerous
substitutions for the primary ingredients. Cakes can also be filled with fruit
preserves, nuts or dessert sauces (like pastry cream), iced with butter cream or
other icings, and decorated with marzipan, piped borders, or candied fruit.

Sweets

Rasgulla:
To prepare rasgulla, the cheese mixture is formed into small balls. These balls are then simmered
in a sugar syrup. It can also be prepared using a pressure cookeror an oven. While serving add a

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drop of rose water (only organic and edible type of rose water, not rose perfume or synthetic
flavors) to enhance the flavor and taste.

Gulab jamun:
Gulab jamun is a sweet, originating in the Indian subcontinent and a type of mithai popular in
India, PakistanIt is made mainly from milk solids, traditionally from khoya, which is milk
reduced to the consistency of a soft dough. Modern recipes call for dried or powdered milk
instead of khoya. It is often garnished with dried nuts such as almonds and cashews to enhance
flavour.

Pizza:
Pizza is a dish of Italian origin consisting of a usually round, flat base of leavened wheat-based
dough topped with tomatoes, cheese, and often various other ingredients
(such as anchovies, mushrooms, onions, olives, pineapple, meat, etc.),
which is then baked at a high temperature, traditionally in a wood-fired
oven. A small pizza is sometimes called a pizzetta.
Pizza is sold fresh or frozen, and whole or in portion-size slices. Methods
have been developed to overcome challenges such as preventing the sauce
from combining with the dough, and producing a crust that can be frozen and reheated without
becoming rigid.
Mozzarella cheese is commonly used on pizza.

Sandwiches:
A sandwich is a food typically consisting of vegetables, sliced cheese or
meat, placed on or between slices of bread, or more generally any dish
wherein bread serves as a container or wrapper for another food type.
The sandwich began as a portable, convenient finger food in the Western
world, though over time it has become prevalent worldwide.
Sandwich, requiring the bread to be sliced from a loaf, and other words
are used for other forms of bread served with fillings (such as roll for a filled bread roll).

SWOT Analysis:

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Strengths
The strengths are:
 The Thickest Milk
 Taste
 Nutritious
 Hygienic
 Packaging
Weaknesses
The weaknesses are:
 Focus Shifted from Main Product to other products
 Lack of Research & Development
Opportunities

The Opportunities are:

 Target market has big profit margins.
 Bright scope of dairy products.

Threats:
 Big competitors
 Inefficient labor

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